How does your method work?

You transfer the design, either by ironing it on from photo paper printed in a laser printer or by drawing it with sharpie, then you drop the board in ferric chloride (room temp) and shake it every now and then for 20-30 minutes until all the unwanted copper is gone. Nowhere near as effective as the professional method, but it's cheap (like $20 for supplies) and less dangerous. However, it apparently doesn't work very reliably...

And btw, I finally finished setting up the circuit on a protoboard, it will be less than 2" by 2" once I trim down the board. I've got it set up with a 5V regulator pretending to be the xbox and a PC fan as the 360 fans and it seems to work perfectly!

Put a fish tank heater in the acid, it speed up the reactions and makes it dissolve faster.

How hot is good? From a quick search I found some that heat to 78 F and some up to 93 F. I would assume hotter is better right?
And won't the acid mess it up, or no?

The warmer the faster.

Acid can't eat though glass so just make sure you get a heater with a glass covering. Also a Fishtank bubbler helps heep the mixture nice and even.

I still have one concern about this, what happens if you turn the console back on before the 555 times out? The fans would still be connected to 5V which wouldn't be a problem, but the fan control line would be connected to 5V which could raise the voltage of the whole 5V line couldn't it? Doesn't the fan voltage change while the xbox is running?

Maybe have a switch?
What about having the acid in a bowl over a hot pan of water?

Do the two fans ever go different speeds, or are they always fed the same voltage?
As for the timeout issue, a button across the timing resistor leads would momentarily cut the resistance to zero and make the timeout 0 seconds. That would be a cut-off button if you ever wanted to stop the fans while they were being run by the 555.

The voltage is the same for both fans.
Maybe you'll have to do some testing about turning the console on and off.

Yeah probably, it's just that I only have my one xbox and I don't want to break it...
It seems like at least the PSU would do something if the 5V line was higher than it should be, like when the light turns red if one of the lines is shorted. I'll also test to see what voltage the fans get while the console's doing different things. Probably next weekend, I'm back in school now...
It would be pretty easy to wire in the sync button to act as the fan cutoff

You missing a very simple device, how do you keep current from flowing backwards? How about a..... DIODE!!!!

Ok, so a diode would go between the fans and the 5V source to keep the possibly higher voltage on the fan side, away from the 5V line?

Between the fan port and whatever, it might be a good idea to do the same thing for the 5V line just incase

Ok thanks
I just discovered BatchPCB.com, so if this PCB design works I might try a 2-sided board from there with updated components/design

I don't mean to nag and I'm not even in any hurry, but SR2K do you know when those PCBs will be done?